Process for coal-gasification and making pig iron

ABSTRACT

In a melting/gasifying furnace including a coke-filled layer, coal is gasified by oxygen blown through tuyeres into a hot reducing gas which is caused to ascend through the coke-filled layer so as to melt reduced iron supported on the top of the coke-filled layer. The resulting molten iron flows down through the coke-filled layer, and is collected in the lowermost region of the coke-filled layer and discharged therefrom, while the hot gas is recovered. The thus recovered gas is fed into a shaft reduction furnace to reduce iron ores, and the thus formed reduced iron is supplied into the melting/gasifying furnace. In addition to the coal, a variety of fuels mainly comprising carbon and hydrogen such as heavy oil, natural gas, etc. are used for gasification. The fuel is blown through the tuyeres and/or charged through middle openings disposed above the tuyeres.

This application is a continuation of application Ser. No. 372,147 April27, 1982 now abandoned.

FIELD OF THE INVENTION

The present invention relates to a process and apparatus for theproduction of pig iron by melting semi-reduced iron or reduced iron withhigh efficiency using fuel composed mainly of carbon and hydrogen and,at the same time, of a reducing gas composed mainly of carbon monoxideand hydrogen. The furnace according to the present invention ishereinafter referred to as the melting/gasifying furnace.

The present invention relates further to a process and system for theproduction of pig iron, which are carried out and applied with highproductivity and thermal efficiency comparable to those of a blastfurnace process and which make the use of raw materials of low qualitypossible by using a combination of the melting gasifying furnace capableof gasifying coal etc. and melting reduced iron, and a reduction furnacefor reducing iron ores.

Still further, the present invention relates to a process and apparatusin which the melting/gasifying furnace is incorporated so as to producea reducing gas from fuel composed mainly of carbon and hydrogen withgood efficiency.

BACKGROUND OF THE INVENTION

The prior art concerning the melting of reduced iron by a reducing gasgenerated in situ in a furnace and the recovery of the reducing gasincludes followings:

1. Cupola

Coke is burned by hot air to generate a hot gas which is then passedupwardly through a coke-filled layer to melt an amount of iron retainedtherewith. The by-product gas obtained is a low-calorie gas rich in N₂and CO₂.

2. Process of Korfstahl, West Germany (JP Openlaying No. 55-94408)

Coal and hydrocarbon-type fuel are gasified by oxygen and steam to forma hot gas which is, in turn, passed upwardly through a coal charfluidized bed to melt semi-reduced iron on the top thereof, and the hotgas is recovered.

3. Process of Stiftersen, Sweden (JP Openlaying No. 49-110519)

Oxygen and hydrocarbon-type fuel, together with semi-reduced iron, areblown into a coke-filled layer or carbonaceous reducing agent-filledlayer in which the oxygen and the fuel is burned to generate a hot gas,by which iron is melted. Gas reformation is then effected by steam andcarbon, using the sensible heat of the hot gas.

These processes of the prior art have the following disadvantages: Inthe cupola process, the by-product gas obtained is a low-calorie gasrich in N₂ and CO₂, and cannot be used as a reducing or fuel gas.

The second process designed to melt semi-reduced iron resorts to asystem in which a coal char fluidized bed is formed, and an amount ofsemi-reduced iron on top thereof is heated and melted by the ascendinghot gas.

However, the coal char fluidized bed is unstable and poor in thesemi-reduced iron retaining power. Hence, it is not expected to bear thesemi-reduced iron on the coal-char fluidized bed for a longer period oftime. As a result, the iron should be melted in the possible shortesttime with a large amount of the hot gas, which means that the thermalefficiency of melting is low.

The third process resorts to a system in which semi-reduced iron,together with oxygen and hydrocarbon fuel, is blown into a carbonaceousreducing agent-filled layer through tuyeres to burn the hydrocarbon fuelwith oxygen thereby obtaining the hot gas, and the iron is melted by thesensible heat of the resulting hot gas. The gas consumed for melting ofsemi-reduced iron has a temperature higher than the melting pointthereof. Therefore, the combustion heat of oxygen and hydrocarbons isnot effectively used for melting of sem-reduced iron. As well-known inthe art, the production of pig iron by reduction and melting of ironores is carried out according to two production systems; one whereiniron ores are gas-reduced in the massive state followed by melting, andthe other wherein iron ores are heated and melted and thereafter reducedwith the aid of a solid reducing agent. The former system is typicallythe blast furnace process, and the latter is typically themelting/reducing process.

However, the melting/reducing process has the disadvantages that thereduction of molten iron ores with the solid reducing agent involves aconsiderably endothermic reaction which renders a stable supply of heatinto a reaction bath very difficult, and that there is a marked erosionof refractory materials due to molten iron ores. Hence, in the art noprocess exhibits a productivity and economy comparable to those of theblast furnace process.

Like the blast furnace process, on the other hand, the production systemin which iron ores are gas-reduced and thereafter melted is advantageousin that the gas reduction of iron ores is a certain exothermic reactionwhich proceeds in a stable manner, and in that the melt has a reducedcontent of iron oxides thus posing little or no problem in connectionwith the erosion of refractory materials in comparison with themelting/reducing process. In addition, the blast furnace processexhibits a very high thermal efficiency due to the fact that thegas-reduction and melting of iron ores are carried out in the samevessel, and reduces the consumption of energy if a by-product gas isrecovered for another purposes.

As well-known in the art, however, the blast furnace process requiresthe use of coke of high quality, such as with high strength or lowreactivity, so as to ensure good permeability in the furnace and stabledescending of the stock therein. The production of these cokesinevitably needs a feed of coking coal of high quality and high energyfor coking. The agglomerated iron ores used should also have a highstrength and excel in the softening properties at high temperatures.

There is now an increasing demand for the process of the production ofpig iron with the productivity and thermal efficiency bearing comparisonwith those of the blast furnace process as well as with thepossibilities of applying raw materials of low quality. Such a processwill be of great significance with the future of natural resources inmind and there have been many attempts to investigate a new process.

In the process for the production of gas by combustion of solid fuelssuch as coke and coal, in general, the higher the reaction temperature,the better the gasification efficiency will be. With the prior artgasifying furnace, however, it is impossible to effect high-temperaturecombustion since, as the reaction temperature rises, the resulting ashesare converted into a melt which is very difficult to treat. A typicalexample of the gasifying process as referred to above is the Lurgiprocess using a static bed furnace operated under pressure. The Lurgiprocess is characterized in the use of a static bed furnace, and has theadvantages that the gasification temperature is as low as 1100° C.; theremoval of ashes is relatively easy; the amount of dust generated is byfar less than that in the case of a fluidized bed furnace; and etc.However, this system has the following demerits: The yield of methane islow, resulting in that an appreciable burden is imposed on methanizationso that no high calorie-gas is obtainable; neither fine coal nor cokingcoal is used; difficulties are encountered in the up-scaling of thesystem size; and the like. In this connection, it is noted that thecombustion temperature in the Lurgi process is as low as 1100° C., withthe gasification efficiency being low as a consequence, and theresulting gas has a CO₂ content of about 30%, thus remarkedly rich inCO₂.

OBJECT OF THE INVENTION

An object of the present invention is to provide a novel process andapparatus (a melting/gasifying furnace) for generating a reducing hotgas in situ to melt reduced iron and for recovering the reducing gas.

Another object of the present invention is to provide a process forproducing pig iron which makes it possible to decrease the overallenergy consumption with good efficiency by recovering a useful reducinggas obtained as a by-product.

Yet another object of the present invention is to provide a novelprocess and system for making pig iron starting from iron ores byeffecting the production of reduced iron and melting of the resultantreduced iron with the aid of a reducing gas generated in themelting/gasifying furnace, which are capable of saving in energy,decreasing the coke ratio and using raw materials with a lawer quality.

Still further ofject of the present invention is to provide a processand apparatus for the efficient production of a reducing gas composedmainly of carbon monoxide and hydrogen by employing fuel composed mainlyof carbon and hydrogen such as solid fuel, for instance, coal and coke.

Other objects of the present invention will become apparent from areading of the following explanation.

SUMMARY OF THE INVENTION

In what follows, the term "reduced iron" shall comprise semi-reducediron, unless otherwise stated. The term "melting/gasifying furnace"shall generally describe a furnace essentially designed to gasify insitu fuel into a reducing hot gas by oxygen, to melt reduced iron withthe aid of a coke-filled layer, and to recover the reducing gas, unlessotherwise specified in the disclosure.

Unlike the aforesaid conventional processes, the present inventioncontemplates burning and gasifying an amount of fuel mainly comprisingcarbon and hydrogen by oxygen into a reducing hot gas composed mainly ofCO and H₂ in a melting/gasifying furnace and melting reduced iron withthe aid of a coke-filled layer into molten iron by making use of thesensible heat of said hot gas.

More specifically, the (first) process for the production of molten ironaccording to the present invention uses the melting/gasifying furnaceprovided therein with a coke-filled layer including therein voids inwhich the gas flows countercurrently to the molten iron and slag, andthe coke-filled layer bearing an amount of unmolten iron on the topthereof, and comprises burning and gasifying fuel mainly comprisingcarbon and hydrogen by oxygen and, optionally, steam in the lower regionof the coke-filled layer to form a hot gas mainly comprising carbonmonoxide and hydrogen, causing the hot gas to ascend through thecoke-filled layer to melt the reduced iron followed by the recovery ofthe hot gas, and causing the molten iron formed by melting of thereduced iron and the iron oxide-containing slag to flow down in thecountercurrent contact with the upward hot gas flowing through thecoke-filled layer, thereby obtaining molten pig iron.

In the countercurrent contact, the iron oxides and other metal oxides inthe slag are reduced by coke, whereon the carbon of the coke isdissolved in the molten iron. The resulting molten pig iron and slag arecollected in the lower most region of the melting/gasifying furnace fortheir extraction.

The (first) melting/gasifying furnace for the realization of the firstprocess of the present invention aiming to produce molten pig iron andgasify fuel comprises

a furnace main,

a top inlet for the introduction of reduced iron, coke and auxiliarymaterials and a gas outlet, which are provided in the top portion ofsaid furnace main,

outlets for the discharge of molten pig iron and slag provided in thebottom portion of said furnace main,

a coke-filled layer provided in a major portion of said furnace main,said layer including therein voids through which a gas flows incountercurrent contact with molten iron and slag, and said layer bearingan unmolten stock charged through said inlet on the top thereof,

a tuyere or tuyeres for blowing oxygen, fuel comprising mainly, carbonand hydrogen and, if required, slag forming material and/or steam, saidtuyere(s) being provided in the side wall portion corresponding to thelower region of said coke-filled layer, and

a combustion zone or zones provided in front of said tuyere(s),

a melting section borne on said coke-filled layer and comprising a stockof reduced iron, coke and auxiliary materials charged through said topinlet, and

a hearth formed in the lowermost region of said furnace main.

The inventive second process is a modification of the inventive firstprocess, wherein the gasification of fuel is effected substantiallyoutside of the outer periphery of the lower region of the coke-filledlayer.

The furnace desinged to carry out the inventive second process includesmiddle opening(s) provided in the side wall above the tuyere(s), throughwhich are introduced solid fuel and, if required, slag-forming materialetc., and combustion zone(s) formed of a charge of solid fuel andprovided substantially outside of the outer periphery of the lowerregion of the coke-filled layer.

The inventive third and forth processes (for the gasification of fuel)are basically analogous to the first and second gasification processes,respectively, wherein the ashes originating from fuel are melted,slagged and flowed down together with, i.e., with the aid of, molteniron, and the resulting molten iron and slag are collected in thelowermost region of the furnace for their extraction. These modifiedprocesses are best suited for use in the gasification of solid fuel suchas coal, coke, etc. and realized by employing the first or secondmelting/gasifying furnace. The resulting reducing gas is a hot gasmainly comprising carbon monoxide and hydrogen, which is useful as afuel, reducing or feed gas as a raw material.

The inventive fifth or sixth system process employs a combination of thefirst or second melting/gasifying furnace with a shaft reduction furnace(first or second system ) to introduce the reducing gas recovered fromthe melting/gasifying furnace into the shaft reduction furnace whereiniron ores are reduced into reduced iron, and to admit the reduced ironinto the melting/gasifying furnace wherein it is converted into moltenpig iron. The shaft reduction furnace may be of either moving - orstatic-bed type.

With the fifth and sixth system processes, it is possible to make molteniron with an amount of energy that is analogous to or less than thatrequired in the blast furnace process and with the use of a feed of rawmaterials of quality and/or grade that are lower than those of materialsdemanded in the blast furnaces process, as well as with an reduced cokeratio in comparison to that process.

The present invention will now be explained with reference to theembodiments illurstrated in the accompanying drawings for the purpose ofillustration only; the present invention is not limited theretowhatsoever.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a longitudinal section of one embodiment of themelting/gasifying furnace used in the present invention;

FIG. 2 is a longitudinal section of another embodiment of themelting/gasifying furnace;

FIG. 3 is a flow chart illustrative of the system for the production ofpig iron comprising a combination of the melting/gasifying furnace withshaft reduction furnace;

FIG. 4 is one example illustrative of the flow chart of FIG. 3, in whichthe melting/gasifying furnace of FIG. 2 is applied;

FIG. 5 is a view showing yet another embodiment of the melting/gasifyingfurnace; and

FIG. 6 is a graphical view showing the relationships between variousparameters including the amounts coke, lime, pig iron produced, gasgenerated and combustion gas per Nm³ of O₂, which vary in relation tothe amount of coal to be supplied.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS FIRSTMELTING/GASIFYING FURNACE AND PROCESS

A coke-filled layer bears an amount of reduced iron on the top thereof,the reduced iron being melted by an ascending hot gas, and is useful formaking effective use of the sensible heat of the hot gas. Thiscoke-filled layer serves to maintain the reduced iron at a high leveland to produce satisfactory molten iron, when both the molten ironformed by melting of reduced iron and the iron oxide-containing slagflow down through the coke filled-layer in the countercurrent relationto the ascending hot gas for the reduction of iron oxides and thecarburizing of molten iron.

In accordance with the present invention, the fuel composed mainly ofcarbon and hydrogen is gasified into a combustion gas composed mainlyor, preferably, substantially consisting of CO and H₂ by oxygen and,optionally steam, for the following primary reasons.

1. The gas formed is a high-calorie, hot and reducing gas composedmainly of CO and H₂. The use of air is unpreferable since the resultinggas assumes a high N₂ content (%).

Recovering and further utilization of this hot reducing gas makes greatcontribution to improvements in the overall energy efficiency.

2. If use is made of oxygen, it is then possible to obtain a gas havinga high temperature sufficient to melt reduced iron by blowing it intothe furnace at normal temperature. However, the use of air requirespre-heating at about 500° C. or higher.

3. Steam is used at need to control the temperature of the gasgenerated, and ascribable to an increase in the hydrogen content of thegas generated, when a carbon-rich fuel such as coal or coke is used.

The term "fuel(s)" refers to solid fuel such as coal or coke, liquidfuel such as heavy oil or tar and gaseous fuel such as natural gas, cokeoven gas or the like. As the fuel, coal, coke (particularly pulverizedcoal, coke breeze) etc., i.e., solid fuel may be employedadvantageously.

When the fuel used is coal, the hot gas formed in the combustion zonesand composed mainly of carbon monoxide and hydrogen has the followingcomposition: CO: 60-75%, H₂ : 25-35% and CO₂ plus N₂ : about 5%.

It is here noted that the hot gas composition may fluctuate more or lessdepending upon the amounts of fuel and steam blown in, etc. The maximumtemperatures in the combustion zones are of the order of 2000° to 2500°C., usually about 2300° C. In this case, the gas recovered after meltingof reduced iron has a CO content somewhat larger than that of theaforesaid hot gas (as generated in the combustion zones), and assumes acomposition of, e.g., CO: 65-80%, CO₂ plus N₂ : 5% and H₂ : 20-30%. Thegas recovered should also have a temperature ranging normally from 900°to 1000° C., preferably about 950° C., depending upon the chargetemperature, the operating conditions and other factors. Thishigh-calorie hot gas recovered is advantageously used as a reducing,fuel or chemical material gas or the like gas in the successiveprocesses.

Usually, the molten iron formed flows down thorugh the coke-filled layer(functioning as a heating section) at 1500° to 1600° C., and generallyassumes a resultant composition of C: 4.5%, Si: 0.2% Mn: 0.2%, P: 0.12%and S: 0.03% (in the case of using pulverized coal as the fuel andsemi-reduced iron as a stock). During it flows down through thecoke-filled layer, the molten iron is desulfurized by the slag whosebasicity is adjusted to a suitable degree (about 1.0 to 1.5), and isfinally collected in a hearth formed in the lowermost region of thefurnace main, which may include the bottom region of the coke-filledlayer.

The stock charged is reduced iron, and an additional amount of coke isreplenished to make up for a coke loss of the coke-filled layer, while agiven amount of a slag-forming material (flux) such as limestone whichis counted as `auxiliary materials` hereinafter is added for theadjustment of the fluidity and basicity of slag. The auxiliary materialsfurther encompasses other known additives which are employed in makingpig iron.

The reduced iron which can be advantageously used with the inventivemelting/gasifying furnace is one having a metallization (M.Fe/T.Fe) ofabout 75% or higher, and may be a mixture of reduced iron with ores.

The oxygen used is preferably pure oxygen (purity: 99% or higher), butindustrial oxygen having an oxygen content of 96 to 97% or even about90% or higher may be employed on account of economical and otherconsiderations.

The voids or intersticial spaces in the coke-filled layer may be of sucha nature that the ascending hot gas comes in countercurrent contact witha down-flow of the molten iron formed by melting of reduced iron and theiron oxide-containing slag. The coke used may be of a diameter of 30 mmor more, which is variable in dependence on the size of the furnaceapplied, the operating conditions and otehr factors. The height of thecoke-filled layer is determined taking into consideration thecarburizing of molten iron, i.e., dissolving carbon of the coke in themolten iron, the reduction of the oxides in the slag and other factors,and may be about 4 to 5 m, as measured from the puyeres level, in thecase of a furnace with a daily production capacity of 2000 tons.

The coke-filled layer has a strength sufficient to maintain the stock ofreduced iron, coke and auxiliary materials such as lime etc. on the topthereof, and occupies a main portion in the furnace. It is understoodthat use may be made of semi-coke.

A suitable number of combustion zone or zones for the gasification offuel is/are provided in front of the tuyere(s) preferably formedradially in the furnace side wall corresponding to the lower region ofthe coke-filled layer. The temperatures in the combustion zones arecontrolled to given values by an amount of steam injected through thetuyeres.

The coke-filled layer may usually be of a circle or polygon in itsholizontal cross-section depending upon the cross-section of thefurnace. The tuyere is open outward of each combustion zone, throughwhich are blown fuel and oxygen and, if required, steam, as well as, ifdesired, slag-forming material such as powdered limestone.

The coke-filled layer carries a load from its upper region at the centerof its lower region, and has therein voids of a size suitable forpermitting both the gas and the slag to flow therethrough. In the lowestregion of the furnace, there is a hearth for the collection of molteniron and slag.

The coke-filled layer forms the walls of the combustion zones, and isconsumed along with the combustion and gasification of fuel. Hence, anadditional amount of coke is generally replenished through the top inlettogether with an amount of fresh reduced iron.

If required, a slag-forming material such as limestone is suppliedthorugh the top inlet to adjust the basicity, flowability, desulfurizingeffect, etc. of the slag.

The coke-filled layer usually assumes a temperature of about 1800°-2000°C. in the lower region and a temperature of about 1600°-1650° C. in theupper region. The reduced iron and the coke are alternately or inadmixture charged through the furnace top to form a reduced iron layer(or a mixture of it with coke) on the top of the coke-filled layer, andis then melted gradually by the ascending hot gas. The reduced ironselected may be of a grain size of 5 mm or more so as to ensure goodpermeability and prevent its take away by the gas flow.

When employing the basic arrangement as mentioned above, the basicparameters applied in the inventive first process are for instance givenin Examples 1 and 2 (pure oxygen, pulverized coal as fuel, andsemi-reduced iron as stock).

In operation, the pressure in the furnace may be on a low level of,e.g., 1 Kg/cm² or more, provided that the pressure for further use ofthe recovered gas is neglected, but may vary between 3 and 5 Kg/cm² forusual purposes.

According to the present invention, it is thus possible to gasify fuelcomposed mainly of carbon and hydrogen, such as coal or heavy oil, bymeans of oxygen and, if required, steam, to melt reduced iron on top ofthe coke-filled layer into molten iron, and to recover a hot gascomposed mainly of carbon monoxide and hydrogen. The present inventionis effective not only for melting of reduced iron, etc., but also foremploying fuel such as coal by means of direct combustion andgasification thereof as well as the gas recovered is advantageously usedfor other purposes of concern.

The present invention is distinguished over the prior art blast furnaceprocess in that a larger amount of fuel such as pulverized coal, tar orheavy oil is gasified by pure oxygen for melting reduced iron.

Other advantages of the present invention are:

1. About 60% or more of the total input fuel can be fuel other thancoke.

2. Larger amounts of pulverized coal and other fuel can be blown throughthe tuyeres.

3. There is no deterioration in the reaction of coke since melting of(semi) reduced iron is aimed at. This makes the use of low-strength cokepossible.

4. Use may be also made of semi-coke. Therein, a semi-coke productleaving the step of the production of reduced iron, which is still mixedtherewith, may be used as such.

5. The furnace used is of simple construction, and decreased in size.

6. The sulfur content in molten iron can be maintained to 0.03% or lessby controlling the composition of slag by the addition of a slag-formingmaterial such as limestone, etc.

7. The thermal efficiency of this process is enhanced sincecountercurrent heat exchange between the hot combustion gas and themolten iron and slag takes place with the aid of, i.e., through thecoke-filled layer.

8. The practical investigations revealed that the resultant CO₂ amounts1-2% in the recovered gas (pulverized coal blown through tuyeres, O₂ :pulverized coal ratio=1 Nm³ : 1 kg)

The present invention will now be elucidated with reference to thefollowing examples. In the following examples the embodiments of thepresent invention will be shown as designed furnaces or systems, orcalculated, operation data for practical use, which were scaled up basedon the test results.

EXAMPLE 1

Referring to FIG. 1, a furnace shown generally at 1 has an inlet 2 forthe introduction of semi-reduced iron and coke and a gas outlet 3 in thetop portion, a plurality of tuyeres 4 for the injection of oxygen andsteam as well as pulverized coal and, if required, powdered limestone inthe side wall, and molten iron and slag outlets 5, 6 in the bottomportion. The furnace 1 is a substantially cylindrical furnace whoselower part is of a somewhat larger diameter, and is provided with theinlet 2 and the gas outlet 3 in the top portion. The tuyeres 4 areprovided in the side wall of the upper part in the furnace portion of alarger diameter, and the molten iron outlet (tapping hole) 5 and slagoutlet (cinder notch) 6 (from above) are provided in the furnace sidewall below the level of tuyeres 4.

An amount of coke is charged into the furnace 1 through the top inlet 2.The furnace 1 is previously loaded with a coke-filled layer b retainingtherein voids. On the layer b is placed a layer a in which an amount ofreduced iron is charged in unmolten state, and below the layer b arepositioned a molten slag layer c and a molten iron layer d. A pluralityof combustion zones e are formed in front of the tuyeres 4, in the lowerregion of the coke-filled layer.

This furnace is typically of the following dimensions.

Inner Diameter of Tuyeres: 190 mm

Number of Combustion Zones in front of Tuyeres: 4

Upper Section Inner Diameter of the Coke-Filled Layer: 4 m

Lower Section Inner Diameter of the Coke-Filled Layer: 6 m

Distance Between Reduced Iron-Charged Layer and Tuyere Level: 5 m

Oxygen 9 and fine coal 10 are blown into the furnace 1 through thetuyeres 4, and reduced iron 7 and coke 8 (having a particle size of 40mm or more) are charged together with limestone 13 through the top inlet2. The furnace is operated at an internal pressure (within thecombustion zones) of 5 Kg/cm². The generated gas 12 is recovered throughthe gas outlet 3, and the molten iron of 1500° C. is discharged throughthe outlet 5 provided in the hearth. The slag is occasionally dischargedthrough the outlet 6. The operation data showing amounts of thematerials and fuel to be used and the products obtainable are summarizedin Table 1.

The reduced iron 7 has a particle size of 5-15 mm and a metallization(M.Fe/T.Fe) of 90%, the oxygen used a purity of 99%, the coke used afixed carbon content of 88.9% and an ash content of 10.6%, and thepulverized coal used a carbon content of 52.1%, a volatile content of30%, an ash content of 15.0% and a moisture content of 2.2%. Thecomposition of the reduced iron is shown in Table 2.

                  TABLE 1                                                         ______________________________________                                        OPERATION DATA                                                                (Per 1 ton of Fe in molten iron)                                              ______________________________________                                        Oxygen       373.2 Nm.sup.3   Blown through                                   Pulverized coal                                                                            456.1 Kg         tuyeres 4                                       Powdered limestine                                                                         108.9 Kg                                                         Reduced iron                                                                              1288.8 Kg         Charged through top                                                           inlet 2                                         Coke         241.2 Kg                                                         Gas recovered                                                                             1209.7 Nm         Recovered through gas outlet 3                         CO       75.4%                                                                CO.sub.2  1.9%                                                                H.sub.2  22.3%                                                                N.sub.2   0.4%                                                         Temperature 950 ° C.                                                   Calorie     2850 KCal/Nm.sup.3                                                Molten pig iron                                                                           1048 Kg       Discharged through                                                            outlet 5                                                   C          4%                                                                 Si        0.2%                                                                Mn        0.2%                                                                P        0.12%                                                                S        0.03%                                                         Slag         408.8 Kg     Basicity: 1.2                                       ______________________________________                                    

                  TABLE 2                                                         ______________________________________                                        Composition                                                                              T.Fe     Feo    M.Fe    SiO.sub.2                                                                          CaO                                   ______________________________________                                        %          77.6     10     69.8    7.06 6.89                                  ______________________________________                                    

EXAMPLE 2

The furnace similar to the furnace 1 of Example 1 is operated mainlywith reduced iron (M.Fe/T.Fe : 85%) and semi-coke (81.5% fixed carbon,8% volatile content and 10.5% ash). Additionally steam is blown throughthe tuyeres. The results are given in Table 3.

                  TABLE 3                                                         ______________________________________                                        Oxygen      328   Nm.sup.3 /t.Fe                                                                          Molten iron                                                                              1050                                                               formed     Kg                                     Pulverized Coal                                                                          393.5  Kg/t.Fe   C     4.5%                                        Steam      7.2    Kg/t.Fe   Si    0.2%                                                                    Mn    0.2%                                        Reduced iron                                                                             1349   Kg/t.Fe   P      0.12%                                      Semi-Coke  205    Kg/t.Fe   S      0.03%                                                                  Temp. 1500° C.                             Gas recovered                                                                            1082   Nm.sup.3 /t.Fe                                                                          Amount of slag                                                                            387                                   CO         67.6%        Semi-reduced Kg                                       CO.sub.2   2.0%          iron                                                 H.sub.2    30.0%        T.Fe    74.15%                                        N.sub.2    0.4%         M.Fe    63.03%                                        Temperature                                                                              950° C.                                                                             FeO     14.3%                                         Calorie    2813   Kcal/Nm.sup.3                                                                           SiO.sub.2                                                                           6.8%                                                                    CaO   10.2%                                       ______________________________________                                    

SECOND MELTING/GASIFYING FURNACE AND PROCESS

The second process of the present invention is a modification of thefirst process, wherein the gasification of fuel is effected incombustion zone or zones located substantially outside of the lowerregion of the coke-filled layer. The furnace designed for therealization of the second process includes middle opening or openings,provided in the furnace wall above the tuyere(s), for the introductionof solid fuel and, if required, slag-forming material etc., and acombustion zone or zones formed in a layer of the solid fuel chargedthrough the middle openings (referred to "solid fuel charge"hereinafter) located substantially outside of the lower region of thecoke-filled layer.

FIG. 2 is a schematical view of the second melting/gasifying furnaceshown generally at 1a, which is a modification of the first furnace ofFIG. 1. As outlined as above, the furnace 1a includes a plurality ofmiddle openings 15, formed above tuyeres 4, for the introduction ofsolid fuel such as coke or coal, slag-forming materials such aslimestone, and the like. In front of the tuyeres 4, there are aplurality of combusion zones e formed of the solid fuel charge suppliedthrough the openings 15. The coke (i.e., fuel coke) supplied through theopening 15 may of the grade available for fuel.

As the solid fuel, only coal may be charged through the openings 15.However, care should be taken of avoiding hanging of the solid fuelcharge, i.e. a coal-filled layer g due to its over-heating by blowingsteam 11 through the openings 15 or into the vicinity thereof, ifnecessary.

Like the first furnace, powdered fuel such as pulverized coal or cokebreeze, or other liquid or gaseous fuel may be blown thorugh the tuyeres4 at need (however, preferred). Particular preference is given toblowing-in of pulverized or fine coal. In the case of injectingpulverized coal, coke breeze, etc. through the tuyeres 4, a slag-formingmaterial 13a such as limestone in the powder form is simultaneouslyblown in to promote rapid formation of slag, improve the fluiditythereof, and facilitate discharging thereof from the combustion zones e.

The second process (furnace) provides additional advantages that thesolid fuel such as coal, coke and the like is used in an amount greaterthan that used in the first process for gasification; the cokeconsumption of the lower region of the coke-filled layer is reduced dueto the fact that the combustion zones are formed of (and surroundedwith) the layers g filled with the solid fuel supplied through themiddle openings 15; etc.

The above-mentioned combustion zones are formed as follows.

In case where, in order to decrease the consumption of coke made ofcoking coal, pulverized coal is burned by blowingin pulverized coaltogether with oxygen and steam through the tuyeres, the combustion gasassumes extremely high CO₂ and H₂ O contents if the combustion zones arenot filled with coke or coal resulting in consuming coke in thecoke-filled layer by reacting therewith. In case where the combustionzones are densely filled with coke or coal, on the contrary, CO₂ and H₂O gas in the combustion gas are converted into CO and H₂ gas by reactingwith coke or coal in the combustion zone thus attaining a high calorificvalue; however, the generating combustion gas flow encounters resistanceor obstacle in the combustion zones, and disturb the race ways to beformed in the frontal region of the noses of the tuyeres to such anextent that no stable combustion is assured. These problems are overcomein the second process in which the combustion zones are formed of orfilled with coke of coal (solid fuel) to obtain a high-caloriecombustion gas, and a frontal and lower race ways of the combustionzone(s) are formed of the coke-filled layer which is filled with coke(charged through the top inlet having a grain size larger than that ofcoke in the combustion zones is formed to stabilize combustion andproceed the reaction of CO₂ generated in the comustion gas in said zoneswith coke to form a gas rich in CO and having an extremely low CO₂content.

The coke-filled layer b should always be kept constant by replenishing agiven amount of coke through the top inlet 2.

The ashes originating from the solid fuel such as coke, coal and thelike in the combustion zones are slagged in a stabilized manner by anamount of the slag-forming material 13 such as limestone or quick limefed from above the combustion zones, and flow down towards the furnacebottom through the combustion zones. The feed ratio of limestone may beadjusted, e.g., up to about 1.5 by optionally regulating the ratio ofCaO formed by thermal decomposition of limestone to SiO₂ being a maincomponent of the ashes resulting from coke, coal and the like.

The combustion gas ascends through the coke-filled layer having a grainsize of 50 mm or less, and melt the reduced iron on the top thereof. Atthe same time, the formed slag flows down through the coke-filled layerto the furnace bottom. To this end, a hearth d is formed on the furnacebottom, which is divided into an upper portion for receiving the slags cresulting from the reduced iron and the ashes coming from the combustionzones and a lower portion for receiving the molten pig iron.

FIG. 2 is a schmatical view of the furnace 1a (the second furnace) forthe realization of the second process. The second furnace 1a is afurnace of the shaft type comprising a furnace main, a plurality oftuyeres 4 for blowing-in of oxygen, steam and pulverized coal in theside wall, a plurality of middle openings 15 provided in the side wallabove the tuyeres for the introduction of solid fuel such as coke, coal,limestone, etc., top inlet 2 for charging stock comprising reduced iron7, coke 8 and the like and a gas outlet 3 in the top portion, and amolten iron outlet 5 and a slag outlet 6 in the bottom portion. In frontof the tuyeres 4 there are a plurality of combustion zones e formed oflayers g filled with coke, coal, limestone and the like supplied throughthe middle openings 15, into which combustion zones the pulverized coalblown through the tuyeres is burned together with the filled coke andcoal by oxygen and steam that are, at the same time, introduced throughthe tuyeres 4. In front of the combustion zones there is a heatingsection comprising a part of the coke-filled layer b filled with cokecharged through the top inlet 2. Above the heating section there is amelting section formed of the layer filled with reduced iron chargedthrough the top inlet 2. A hearth d is formed for receiving the moltenpig iron and slag flowing down from the heating section and the moltenashes formed in the combustion zones.

It is noted that the pressure of gas in the above-mentioned furnace isadjustable by a pressure regulating valve provided on a gas recoveryline extending from the outlet 3.

According to the inventive second process, the reducing hot gas havingan extremely low CO₂ content can be generated and recovered, and themolten iron can be converted into pig iron having a low sulfur contentby using the arrangement including the zones for combustion of coke,coal, limestone and pulverized coal and the heating section formed ofthe coke-filled layer, viz., the section in which the gas come intocountercurrent contact with the melt, provided in front of thecombustion zones. In addition, the gasification of coal and the meltingof reduced iron can continuously be carried out over an extended perioddue to the use of the moving bed whose contents are subjected to renewalor replenishing momentarily.

The second furnace may be operated in the following differentoperational conditions:

OPERATION I

Operation for the conversion of reduced iron supplied through the topinlet into powdered reduced iron:

Although this operation is subject to variation depending upon a rate atwhich a gas flows through the melting section, there is no possibilitythat, at a gas flow rate of 1 m/S, even granular reduced iron having agrain size of 10 mm or less may be entrained in the gas and leave thegas outlet. On the contrary, such reduced iron is melted more rapidlythan pelleted reduced iron due to its small grain size. The inventivefurnace is therefore expected to be sufficiently applicable to thisoperation. When reduced iron having a smaller grain size is used,satisfactory results are obtained if the amount of gas to be generatedis decreased by decreasing the amount of oxygen blown through thetuyeres, or if the flow rate of gas passing through the melting sectionis decreased by maintaining the pressure in the furnace at 5 kg/cm² orhigher.

OPERATION II

The inventive furnace can be operated with no supply of coke and coalthrough the middle openings, viz., in a condition where the combustionzones are not filled. With this embodiment, it is possible to burnpulverized coal supplied through the tuyeres in a stabilized manner bythe aid of the heat radiating from the lower region of the coke-filledlayer of the heating section located in the frontal region of thecombustion zones.

In the embodiment, however, the pulverized coal should be used as muchas possible, since the coke forming part of the heating section isconsumed by the CO₂ gas generated in the combustion zones. An increasein the amount of pulverized coal results in a considerable lowering inthe amount of such coke to be consumed up to a half thereof. This isbecause only feeding of coke into the heating section suffices for thedesired results.

OPERATION III

The inventive furnace is applicable to the embodiment wherein limistoneis blown through the tuyeres. According to this operation, powderedlimiestone or quick lime is supplied by blowing them through the tuyeres4 in place of feeding limestone etc. thorugh the middle openings or tomake up the amount of lime supplied through the middle openings. Thepowdered lime is rapidly melted, and mixed with molten ashes originatingfrom pulverized coal, etc., to improve the fluidity of the molten ashes.This results in that the amount of lime to be used can be decreased byabout 10-20% in comparison with the case where the lime is suppliedthrough the middle openings.

OPERATION IV

The inventive furnace is applicable to an embodiment wherein liquid fuelsuch as heavy oil, gaseous fuel such as natural gas or powder fuel suchas powdered asphalt pitch is emplayed as fuel. Such fuels can beemployed substituting for pulverized coal or as a mixture therewith.

In the case of using heavy oil as fuel, it is required to decrease theamount of steam blown through the tuyeres, since it absorbs moredecomposition heat than pulverized coal does. However, the amount ofheavy oil used is less than that of pulverized coal, since it containslarger amounts of carbon and hydrogen. Natural gas or asphalt pitch maybe used, if the amount of steam used supplied through the tuyeres isregulated so as to maintain the gas generated in the combustion zones ata suitable temperature above 1800° C.

The second process according to the present invention will now beexplained with reference to Example 3.

EXAMPLE 3

Using the furnace arrangement of FIG. 2, the coal is gasified, and thereduced iron is melted into pig iron with the following operation data.Table 4 shows the composition of the pulverized coal, coke and reducediron applied, and Table 5 the composition, amount, temperature, etc., ofthe resultant molten pig iron and the recovered gases.

OPERATION DATA 1. FURNACE ARRANGEMENT

Number of Combustion Zones (Tuyeres): 4

Effective Height (from the bottom to the gas outlet): 10 m

Diameter of Melting Section: 5 m

Effective Volume of Furnace: 350 m³

2. FEED OF MATERIALS AND FUELS

Oxygen: 28 KNm³ /hr

Steam: 1 ton/hr

Pulverized Coal: 28 ton/hr

Coke (charged through middle openings 15): 10 ton/hr

Coke (charged through top inlet): 8 ton/hr

Coal (charged through middle openings 15): 3 ton/hr

Limestone: 7 ton/hr

Reduced Iron: 110 ton/hr

Pressure in Furnace: 5 kg/cmz

TABLE 4

Pulverized Coal C: 75%, H₂ : 5% through 200 mesh sieve: 70%

Coke (charged through middle openings 15) C: 88%, Grain Size: 15 mm

Coke (charged through top inlet) C: 88%, Grain Size: 50 mm

Reduced Iron Metallization: 85%, CaO/SiO₂ : 1.3 Grain Size: 10 mm

TABLE 5

Molten Pig Iron C: 4.5%, Si: 0.5%, S: ≦0.02% Temperature: 1500° C.

Recovered Gas CO: 76%, H₂ : 22%, S: 200≦ppm Temperature: about 1000° C.,Calorie: about 2950 Kcal/Nm³, Dust Content: ≦10 gr/Nm³

According to the present invention, the high quality pig iron for steelmaking is obtained having carbon, silicon and sulfur contents of 4.5%,0.5% and 0.02% or less, respectively, and the high quality gas isrecovered having a calorie of about 2950 Kcal/Nm³, a dust content of 10gr/Nm³ or less and a sulfur content of 200 ppm or less, as will beappreciated from the results of Table 5.

GASIFICATION PROCESS OF FUEL BY MELTING/GASIFYING FURNACE THIRD ANDFOURTH PROCESSES

The first and second processes (furnaces) are designed to effect thegasification of fuel and the recovery of the resulting gas concurrentlyor simultaneously with the melting of reduced iron and the production ofmolten iron. However, the inventive furnaces can also be used mainly forthe gasification of fuel.

FIG. 5 shows one embodiment of the furnaces designed to this end.

The illustrated furnace is basically similar to the second furnace inthat it has a plurality of tuyeres 4, a plurality of openings 15positioned above the tuyeres 4, and a plurality of combustion zones elocated substantially outside of the lower region of a coke-filled layerb and in front of the tuyeres 4, and formed of layers g filled with thesolid fuel charges from the middle openings 15. The gas obtained isagain a reducing hot gas composed mainly of carbon monoxide andhydrogen. To permit effective gasification of fuel such as coal, it isrequired to remove molten ashes which could not easily be dischargedfrom the furnace in the prior art. According to the present invention,the molten ashes are entrained in or carried out by a down flow ofmolten reduced iron, and discharged from the furnace as slag togetherwith molten iron.

The combustion zones e are formed by injection of O₂ or steam throughthe tuyeres 4. Given amounts of coke, coal and limestone are introducedthrough the middle openings 15 into the zones e wherein they are burned.The resulting hot gas passes upwardly through the coke-filled layer bfilled with low-reactivity coke to melt reduced iron by the sensibleheat thereof. The thus generated reducing hot combustion gas composedmainly of carbon monoxide and hydrogen is recovered from the gas outlet3. On the other hand, the molten ashes formed in the zones e, the meltcomprising CaO, a main component of limestone, and the reduced ironmelted on the top of the coke-filled layer b flow down through the layerb into the hearth d, and discharged through the outlets 5 and 6.

The problems as encountered in the prior art concerning the gasificationof coke or coal by O₂ or air have been eliminated by the presentinvention designed to fill the combustion zones e with the coke- orcoal-charged layers g to obtain a high-calorie gas, and to form thelayer b filled with high-permeable but low-reactive coke in the frontalregion of the zones e to attain stable combustion, whereby thecombustion gas passes through the zones e straight. When thegasification of fuel is primarily aimed at, graphite balls may be filledin the layer b in place of coke.

With the static bed gasification system according to the presentinvention, it is possible to obtain a high-calorie gas having atemperature of as high as 2000° C. by stable combustion of non-cokingcoal or low-strength coke obtained by semi-coking of non-coking coalhardened by a bonding agent. In addition, by the sensible heat of thegenerated hot gas reduced iron can be converted into molten iron, whichentrains therein the ashes resulting from coke and non-coking coal, andis discharged as such in a stable manner. It is noted that the term"static bed" does not exclude the replenishment of coke to thecoke-filled layer as mentioned hereinbefore.

According to the present invention, it is also possible to control thetemperature of the combustion gas in the combustion zones filled withcoke or coal to a suitable value either by regulating the flow rate ofsteam to be injected through the tuyeres 14 or by blowing steam througha separately arranged nozzle 16. When there is a rise in the CO₂concentration in the combustion gas recovered, it is possible toregulate the amounts of oxygen, air of a normal temperature andpulverized coal to be blown through the tuyeres 4.

The present embodiment will now be elucidated with reference to thefollowing example.

EXAMPLE 4

With the melting/gasifying furnace of FIG. 5, the coal is gasified, andthe reduced iron is melted into pig iron. FIG. 6 shows the amount ofcombustion gas recovered, pig iron produced, limestone charged, steamblown and coke used per a charge of coal and the calorific value of thecombustion gas.

From FIG. 6, it has been found that the more the amount of coal, thehigher is the calorific value of the obtained gas corresponding to adifference in the resultant gas volume between coal and coke, and thehigher is the melting power of the gas.

SYSTEM PROCESS FOR MAKING PIG IRON USING A COMBINATION OFMELTING/GASIFYING FURNACE WITH A SHAFT REDUCTION FURNACE FIFTH AND SIXTHPROCESSES

Reference will now be made to the process for making pig iron using acombination of the foregoing melting/gasifying furnace with shaftreduction furnace.

In what follows, the term "iron ores" shall include lump ores andagglomerated ores such as iron oxides in granular or lump form, e.g.pellets or brickets or the like unless otherwise specified.

As already mentioned, any iron melting processes in the prior art exceptfor those resorting to the blast furnace leave much to be desired assuch, and have the disadvantage that the gas recovered from the meltingfurnace is unsuitable in view of efficient reduction of iron ores.

A typical example of the prior art gas reduction furnaces for iron oresis a shaft reduction furnace. The shaft furnace requires the productionsystem of a reducing gas which is specially designed to this end. To putit in another way, special fuel such as natural gas reformed by steam(e.g., manufactured by Foster Wheeler Co., Ltd.) should be used in thisfurnace.

The fifth and sixth processes according to the present invention areaccomplished with a view to decreasing the consumption of energy and thecoke ratio as compared with the blast furnace process and using a feedof low quality and/or grade. According to the present processes, thisobject is achieved by the provision of a process for pig iron makingusing a combination of a gas reduction furnace with themelting/gasifying furnace for the melting of reduced iron and thegeneration of a reducing gas.

As the shaft reduction furnace, use may be made of either the moving bedtype or the static bed type, but preference is given to the moving bedtype furnace. However, a plurality of the static bed type furnaces maybe alternately operated for continuous operation. The present processeswill now be explained with reference to the shaft reduction furnace ofthe moving bed type.

The moving bed type reduction furnace includes a furnace main having aniron ore inlet and a gas outlet in the top portion, a gas injectionopening in the side wall and a reduced iron outlet in the bottomportion. Within the furnace main, there is a layer filled with granulariron oxides supplied through the iron ore inlet. The reducing gas blownthrough the gas inlet flows upwardly through the iron oxide-filled layerand reduces the glanular iron oxides, resulting in granular reducediron. The reducing gas is recovered through the gas outlet, while theresultant reduced iron is discharged through the bottom outlet.

In the combination system of the shaft reduction furnace of the movingbed type and the melting/gasifying furnace, the gas formed in the latterfurnace is used as a reducing gas in the shaft reduction furnace andrecovered, whilst the reduced iron formed in the shaft reduction furnaceis melted in the melting/gasifying furnace. In this way, the overallenergy consumption is decreased or limited, while a feed of low qualityor grade can be used.

More specifically, this inventive process for the production of pig ironcomprises reducing iron ores in the shaft reduction furnace with areducing gas recovered from the melting/gasifying furnace, and meltingthe thus reduced iron into pig iron in the melting/gasifying furnace. Inthe melting/gasifying furnace, the fuel composed mainly of carbon andhydrogen is burned and gasified by oxygen to generate a reducing hot gascomposed mainly of carbon monoxide and hydrogen. The hot gas is allowedto flow upwardly through the coke-filled layer, thereby melting thereduced iron on the top thereof. The molten iron flows downwardlythrough the coke-filled layer, and is converted into pig iron. Thereducing gas is recovered through the top outlet, and supplied into thereduction furnace. It is understood that an extra amount of the reducinggas is discharged to the outside of the system, and used for otherpurposes.

The iron reduced in this shaft furnace assumes a metallization(M.Fe/T.Fe) of about 75% or higher that is useful for feeding to themelting/gasifying furnace. If required, a mixture of reduced iron withfresh iron ores may be fed in the melting/gasifying furnace, taking intoaccount the balance between the metallization of the feed and thecapacity of the reduction furnace.

The shaft reduction furnace may be of the type capable of effectinghigh-pressure reduction. This is because the desired high-pressurereducing gas can be recovered by the adjustment of the pressure in themelting/gasifying furnace. The shaft reduction furnace is preferably ofthe moving bed (or continuous) type, but the reduction furnace of thestatic bed type may be applied, if required. The moving bed typereduction furnace suitable for use in the present invention is, forexample, Midrex process, Armco process, Purofer process or Nippon Steelprocess type furnace.

As shown in the flow chart of FIG. 3 that is illustrative of theprincipal arrangement of the present invention, an amount of iron 7reduced in a shaft reduction furnace 20 is fed into a melting/gasifyingfurnace 1, after cooled at need. In reduction, the shaft furnace isoperated at an internal temperature of 800°-950° C., preferably 900° C.,and at an internal pressure of 2.0-2.5 atm on the condition that apreferably high-pressure reduction system is applied. If required, anamount of fresh iron ores 14 is preheated. Either one of the first andsecond melting/gasifying furnaces is equally applied, (the fifth andsixth process, respectively).

FIG. 4 is a schematical view of the inventive system process (the sixthprocess) in which a melting/gasifying furnace 1a is combined with ashaft reducing furnace 20a of the moving bed type. Reduced iron 7discharged through a bottom outlet 24 in the furnace 20a is optionallycooled (not shown), and fed and stored in a hopper 25 through a feedline 29.

Coke 8 is fed from the top inlet 2 through a feed chute 26 into themelting/gasifying furnace 1a, into which are supplied auxiliarymaterials 13 including a slag-forming material such as limestone and thelike through a chute 27.

Depending upon that the gas produced in the melting/gasifying furnace isused as a reducing gas in the shaft reduction furnace or it is used foranother purposes, the melting/gasifying furnace is maintained at a highinternal pressure ranging from 2 to 5 kg/cm² or more, preferably about 5kg/cm².

The moving bed type shaft reduction furnace 20a is provided therein witha moving bed f. Iron ores or granular iron oxides charged on the top ofthe bed f is gradually heated and melted by an ascending flow ofreducing gas 12 into reduced iron, concurrently, iron ores descendsthrough the moving bed, and is discharged through the bottom outlet 24.The reducing gas passes through a gas outlet 22 and a purifier 28, andis recovered as a by-product gas.

In the case of the static bed type shaft reduction furnace, reductiontakes place in a static bed. The shaft reduction furnace, whether it isof the moving bed type or the static bed type, may preferably beprovided with a cooling zone in the lower portion, or alternately withan external cooling device, to remove the sensible heat of thedischarged reduced iron.

The moving bed type reduction furnace is preferably used since themelting/gasifying furnace can be operated continuously. However, aplurality of the shaft reduction furnaces of the static bed type mayoptionally be operated in a continuous manner by supplying a successivefeed of reducing gas thereinto.

With the arrangement according to the present invention, the reducinggas which has to be separately prepared for the conventional shaftreduction furnace can be prepared in situ, viz., in themelting/gasifying furnace, and recovered at elevated temperature andpressure therefrom, leading to a considerable saving in energy involvedas compared with the conventional shaft reduction furnace. Thus, even acertain small-sized furnace according to the present invention can standcomparison with a large-sized blast furnace from the standpoint ofthermal efficiency.

Composed mainly of carbon monoxide and hydrogen, and substantially freefrom N₂, the reducing gas formed in the melting/gasifying furnace is astrongly reducing, hot gas, which makes a great contribution toimproving the reduction efficiency of the reduction furnace. Thepressure of a feed of reducing gas can be adjusted in themelting/gasifying furnace in association with the required pressure ofthe shaft reduction furnace.

The melting/gasifying furnace is effective not only for melting ofreduced iron, but also for direct use of fuels such as coal, coke(particularly of low quality), etc. by combustion and gasification.

The present invention is fundamentally distinguished over the prior artblast furnace process in that a large amount of solid fuel such aspulverized coal or coke breeze or liquid fuel such as heavy oil or taris, on the one hand, gasified by pure oxygen to melt reduced iron, andthe gas recovered from the melting/gasifying furnace is, on the otherhand, used as a reducing gas in the shaft reduction furnace to reduceiron ores.

In the inventive arrangement, the melting/gasifying furnace is combinedwith the shaft reduction furnace in spaced relation for the followingreasons.

Like the blast furnace, the present invention contemplates producing pigiron in a stable manner with high efficiency by gas-reduction of ironores followed by melting. When the gas-reduction and melting of ironores as well as the combustion and gasification of coke are carried outin a single reactor as is the case with the blast furnace, the coke andcoal receive impact and other loads while they are supplied on the topof the furnace and descend therein, since the interval (height) betweenthe furnace top and the tuyere level amount to about 25 meters. The oresare gas-reduced on the top of the furnace, and melted in the meltingsection about 20 meters below the furnace top, so that a load of about25 tons/m² is applied thereon. Due to such a load, the hot ores underthe melting procedure contract to form a layer markedly deficient inpermeability, referred to as the cohesive zone, which poses difficultiesin descending such as hanging or slipping etc. This is why massive oreswhich excells in the softening properties at high temperatures and formsno large cohesive zone should be used. The coke also receives impact andother loads similarly and if it deteriorates by the time at which itburns out at the noses of the tuyeres, the permeability encountersobstacles. Thus this is the reason why high-strength coke should beused.

To this end, the present invention resorts to the process in which theores are first reduced in the shaft reduction furnace, and then meltedin the melting/gasifying furnace 1. In the melting/gasifying furnace 1,ores whose softening properties at high temperatures are inferior may beused as well, since the reduced iron is melted with no load in themelting section a positioned above the heating section b formed of thecoke-filled layer b. Low-strength coke may be used as well, since thecoke charged through the middle openings 16 positioned above the tuyeresburns out rapidly in the combustion zones in front of the tuyeres.Another reason why low-strength coke is applicable is that the cokecharged through the top inlet 2 to define the heating section b isconsumed only by the carborizing reaction with molten iron and slag,both flowing down through the coke-filled layer, and the reductionreaction of SiO₂, etc., thus receiving no loads and impact caused bydescending as in the blast furnace.

Other advantages of the inventive fifth and sixth processes are:

1. Blowing of oxygen through the tuyeres of the melting/gasifyingfurnace permits blowing of a large amount of pulverized coal (which isapplicable in amount of 1 up to 1.5 kg per Nm³ of O₂) and other fuel.Thus, about 60% or more of the total fuel, i.e., coke for the blastfurnace can be replaced by other fuels.

2. Melting of reduced iron causes no deterioration in the coke reaction,thus enabling low-strength or semi-coke to be used as the coke to becharged.

3. The melting/gasifying furnace can be of simple construction and ofsmall size, and the shaft reduction furnace can be reduced in size dueto high-calorie reducing gas, thus resulting in lowering in theapparatus cost.

4. High thermal efficiency is obtained due to the fact that the heattransfer takes place from the reducing hot gas to granular reduced ironon the coke-filled layer to melt granular reduced iron in themelting/gasifying furnace, and countercurrent heat exchange between thegas and the ores takes place in the shaft reduction furnace.

5. Little or no fused band is formed in both the shaft reduction furnaceas well as the melting/gasifying furnace due to rapid melting of reducediron. Hence, iron ores or agglomerated ores with a low quality can beused.

6. Even when iron ores of low quality are used, it is possible to obtaingranular reduced iron, which has a high metallization of 85 to 96% ormore, and can be supplied as such into the melting/gasifying furnace,since the shaft reduction furnace is incorporated.

7. The overall system inclusive of the shaft reduction furnace is stableto operate, and easy to control.

8. The reducing gas recovered from the melting/gasifying furnace can besupplied as such into the shaft reduction furnace, so that separateproduction and treatment (reforming, treatment for bringing the reducinggas to high pressure and temperature) of the reducing gas are dispensedof, thus leading to a considerable lowering of the energy and costinvolved.

Shortly, the arrangement in which the melting/gasifying furnace isseparated from the moving bed type reduction furnace makes it possibleto apply low-strength coke and low-quality iron ores whose softeningproperties at high temperatures are inferior.

The reasons for using oxygen and pulverized coal in themelting/gasifying furnace are as follows.

Combustion of pulverized coal varies largely depending upon thecombustion temperature and the oxygen concentration of the combustiongas. An 1% increase in the oxygen concentration will result in an about6% increase in the combustion efficiency. Accordingly, provided that theblast is an amount of air having an oxygen content of about 21% as isthe case with the blast furnace, the amount of pulverized coal used perNm³ of oxygen is limited to about 0.3-0.4 kg. In the present invention,however, it is possible to use pulverized coal in an amount of about1-1.5 kg per Nm³ of oxygen, thus leading to a considerable reduction inthe consumption of coke to be burned.

The gas generate by combustion should have a temperature of at least1500° C. to melt reduced iron. Consequently in the case of the blastfurnace the air to be used should be heated in a blast furnace stove. Inthe case where oxygen is used as is the case with the present invention,however, the gas produced has a sufficiently high temperature as aresult that the amount of the gas produced is limited or reduced perunit combustion reaction. This offers an additional advantage in that nohot stove is required, unlike the blast furnace process.

In addition, oxygen can also be blown in the melting/gasifying furnaceby using liquid oxygen as an oxygen source and gasifying it in such amanner that a gas having a pressure of 2-5 kg/cm² (gauge) is obtainedwith no need of any blower, the use of which is inevitable in the blastfurnace process.

As mentioned above, the present invention provides the followingadvantages over the blast furnace process: the consumption of energiesis reduced, the coke ratio drops considerably; low-quality feeds areused due to the absence of the aforesaid fused band; since thepreparation of reduced iron and the melting thereof are carried out inseparate furnaces; and the like.

This embodiment of the system process will now be elucidated withreference to Example 4.

EXAMPLE 4

Pig iron is prepared with the combination system of FIG. 4, providedthat one melting/gasifying furnace and two moving bed type reductionfurnaces are applied. Particulars of the furnaces applied are asfollows:

PARTICULARS OF FURNACES A. Melting/Gasifying furnace

Effective Furnace Volume: 350 m³

Number of Tuyeres: 4

Top Inlet for coke and reduced iron: 1

Middle inlet for coke, coal and lime stone: 1

Combustion zones: 4

Internal Diameter of lower Section: 5 m

Internal Diameter of Melting Section: 5 m

Height of Melting Section: 10 m

Gas Outlet: 1

Internal Pressure: 3˜5 kg/cm²

B. Moving Bed Shaft Reduction Furnace

Effective Furnace Volume: 150 m³

Internal Diameter: 5 m

Ore Inlet: 1

Gas Inlet (about 10 m below the Ore Inlet): 1

Outlet for reduced iron: 1

Gas Outlet: 1

Internal Pressure: 3˜5 kg/cm²

28 KNm³ /hr oxygen, 1 ton/hr steam and 28 tons/hr pulverized coal areblown into the melting/gasifying furnace through the tuyeres. From themiddle openings are charged into the combustion zones 10 tons/hr coke(C: 88%, grain size: 40 mm or less, drum index DI₁₅ ³⁰ =85%), 3 tons/hrcoal (C: 75%, grain size: 40 mm or less) and 5 tons/hr limestone. Equalamounts of reduced iron are discharged from the reduced iron outlets ofthe two reduction furnaces to maintain at about 950° C. the temperatureof combustion gas leaving the melting/gasifying furnace through the gasoutlet. The reduced iron is charged through the reduced iron inlet intothe melting/gasifying furnace via the feed line 29. Basic agglomeratedores (T.Fe: 56%, mean grain size: 12 mm) are introduced into therespective reduction furnaces in the amounts corresponding to thereduced iron discharged. Into the melting/gasifying furnace arereplenished by charging through the reduced iron inlet 8 tons/hr coke(C: 88%, grain size: 40 mm or more, drum index DI₁₅ ³⁰ =85%), thereby tomaintain the upper level of the coke-filled layer forming the heatingsection of the melting/gasifying furnace at a position 10 meters abovethe furnace bottom. Equal amounts of combustion gas having a temperatureof about 950° C. and leaving the melting/gasifying furnace through thegas outlet are injected into the two moving bed type shaft reductionfurnaces. The gas after reduction is recovered through the gas outlet,cooled and de-dusted. The gas is regulated to a pressure of 2 kg/cm², sothat the oxygen injected in the melting/gasifying furnace through itstuyeres attained a pressure of 4.5 kg/cm². The gas leaving this furnacethrough the gas outlet amounts to 87.5 KNm³ /hr, and has a CO content of75%, a H₂ content of 22% and a pressure of 3.2 kg/cm². The gasesrecovered from the two moving bed type reduction furnaces through theirgas outlets have a temperature of about 200° C. prior to cooling andde-dusting, and a composition of CO: 39%, H₂ : 12% and CO₂ : 36%. Thetotal amount of iron ores fed into each shaft reduction furnace of themoving bed type is 140.8 tons/hr, the amount of reduced iron fed intothe melting/gasifying furnace 110.8 tons/hr, the T.Fe 71.1%, and theratio of metal iron relative to the T.Fe (M.Fe/T.Fe) 85%. Thetemperature at which the melting/gasifying furnace is charged is about500° C. The amount of coke fed through the middle openings is 13 tons/hrin total, and the amount of limestone fed therethrough is 4.3 tons/hr intotal. The coke supplied into the melting/gasifying furnace through thereduced iron inlet is 8 tons/hr. As a result, the amount of molten pigiron discharged through the molten iron outlet of the melting/gasifyingfurnace is 83.3 tons/hr, having a composition of C: 4.5%, Si: 0.5%, S:0.02% or less and other impurities elements: 0.5% in total and atemperature of 1500° C. The slag concurrently discharged amounts to 35tons/hr.

The foregoing operation is tabulated as follows:

Materials required for the production of 1 ton of pig iron

Low-quality coke: 216 kg

Coal: 36 kg

Pulverized coal: 336 kg

Oxygen: 336 Nm³

Steam: 12 kg

Limestone: 52 kg

Iron ores (T.Fe: 56%): 1690 kg

By-product gas of 1664 Kcal/Nm³ : 940 Nm³

Actually consumed energy in the system: 2568 Mcal

Energy for preparing oxygen: 572 Mcal

Total energy: 3140 Mcal/t

In this connection, the blast furnace process requires an energy of onlyabout 2800 Mcal per ton of pig iron to be prepared, and seems to belower than that demanded in the present invention by about 340 Mcal.However, the amount of coke required in the pre-treatment demanding muchenergy is about 500 kg/t, i.e., roughly double that used in the presentinvention. In view of the energy consumed in the preparation of coke(the present invention: 260 Mcal, the blast furnace process: 560 Mcal),both processes are considered substantially equivalent. Furthermore, itis evident that the present process is also superior to the blastfurnace process in view of the fact that the latter process needshigh-quality coke and agglomerated iron ores.

The inventive melting/gasifying furnace can be made in size or heightsmaller than the blast furnace, and even a certain small-sized furnaceaccording to the present invention can be operated with high efficiency.

As mentioned above, the processes and systems of the present inventionare of commercially great value.

What is claimed is:
 1. A process for the production of pig iron and thegasification of fuel which comprises:(a) providing a furnace with ashaft-like furnace main; (b) providing a static coke-filled bed packedsubstantially with coke of lump form within the furnace main, thecoke-filled bed containing voids; (c) charging unmolten reduced iron onthe top of the coke-filled bed to form a melting section of a stockborne thereon; (d) providing fuel comprising primarily carbon andhydrogen to the lower region of the said coke-filled bed; (e) supplyinga gas primarily comprising oxygen to said lower region of the saidcoke-filled bed through at least one tuyere, (f) burning and gasifyingthe fuel in the lower region of the coke-filled bed by means ofcombustion with oxygen to thereby generate a reducing hot gas comprisedof primarily carbon monoxide and hydrogen; (g) allowing said reducinghot gas to ascend through the voids of the coke-filled bed and melt thereduced iron in said melting section by the sensitive heat of thereducing hot gas, with the resulting molten iron and ironoxide-containing slag flowing down through the voids of the coke-filledbed in countercurrent relationship to the ascending hot gas, whilehaving the iron oxide reduced by the coke with the carbon in said cokedissolving in said molten iron to thereby convert the molten iron intomolten pig iron, (h) recovering the hot gas, and (i) discharging the pigiron and slag from the lowermost region of the furnace upon collectingsame therein.
 2. A process for the production of pig iron and thegasification of fuel which comprises:(a) providing a furnace with ashaft-like furnace main having an upper region of a smaller diameter anda lower region of a larger diameter; (b) providing a static coke-filledbed packed substantially with coke of lump form within the furnace main,the coke-filled bed containing voids; (c) charging unmolten reduced ironon the top of the coke-filled bed to form a melting section of a stockborne thereon; (d) providing solid lump fuel comprising primarily carbonand hydrogen into the furnace to the outside lower region of saidcoke-filled bed to thereby form a charge of said solid lump fueltherein; (e) blowing a gas comprising primarily oxygen into said chargethrough at least one tuyere toward the coke-filled bed to thereby form acombustion zone or zones substantially within the area of said charge;(f) burning and gasifying the fuel substantially within the combustionzone(s) by the blown oxygen to thereby generate a reducing hot gascomprised of primarily carbon monoxide and hydrogen; (g) allowing saidreducing hot gas to ascend through the voids of the coke-filled bed andmelt the reduced iron in said melting section by the sensitive heat ofthe reducing hot gas, with the resulting molten iron and ironoxide-containing slag flowing down through the voids of the coke-filledbed in countercurrent relationahip to the ascending hot gas, whilehaving the iron oxide in the slag reduced by the coke with the carbon insaid coke dissolving in said molten iron to thereby convert the molteniron into molten pig iron, (h) recovering the hot gas, and (i)discharging the pig iron and slag from the lowermost region of thefurnace upon collecting same therein.
 3. The process of claim 2 in whichsolid fuel in the powder form, liquid fuel or gaseous fuel, or a mixtureof two or more of these fuels is blown through said tuyere(s).
 4. Theprocess as recited in claim 3, in which the powdery solid fuel ispulverized coal, coke breeze, powdered pitch or a mixture thereof. 5.The process as recited in claim 3, in which powdered slag-formingmaterial is additionally blown through said tuyere(s).
 6. The process asrecited in claim 3, in which the coke ratio (coke/total feed of coke andfuel) is less than 40%.
 7. A process for the production of pig iron byreducing iron ores in a shaft reduction furnace with a reducing gasrecovered from a melting/gasifying furnace, and melting the resultingreduced iron in the melting/gasifying furnace to produce pig iron insaid melting/gasifying furnace, comprising the steps;(a) providing amelting/gasifying furnace with a shaftlike furnace main; (b) providing astatic coke-filled bed packed substantially with coke of lump formwithin the furnace main, the coke-filled bed containing voids; (c)charging unmolten reduced iron on the top of the coke-filled bed to forma melting section of a stock borne thereon; (d) providing fuelcomprising primarily carbon and hydrogen to the lower region of the saidcoke-filled bed; (e) supplying a gas comprising primarily oxygen to saidlower region of the said coke-filled bed through at least one tuyere;(f) burning and gasifying the fuel in the lower region of thecoke-filled bed by means of combustion with oxygen to thereby generate areducing hot gas comprised of primarily carbon monoxide and hydrogen;(g) allowing said reducing hot gas to ascend through the voids of thecoke-filled bed and melt the reduced iron in the said melting section bythe sensitive heat of the reducing hot gas, with the resulting molteniron and iron oxide-containing slag flowing down through the voids ofthe coke-filled bed in countercurrent relationship to the ascending hotgas, while having the iron oxide reduced by the coke with the carbon insaid coke dissolving in said molten iron to thereby convert the molteniron into molten pig iron; (h) recovering the hot gas, and (i)discharging the pig iron and slag from the lowermost region of thefurnace upon collecting same therein.
 8. A combination system/processfor the production of pig iron and the gasification of fuel by reducingores in a shaft reduction furnace with a reducing gas recovered from amelting/gasifying furnace, and melting the resulting reduced iron in themelting/gasifying furnace to produce pig iron in said melting/gasifyingfurnace, comprising the steps;(a) providing a melting gasifying furnacewith a shaftlike furnace main having an upper region of a smallerdiameter and a lower region of a larger diameter; (b) providing a staticcoke-filled bed packed substantially with coke of the lump form withinthe furnace main, the coke-filled bed containing voids; (c) chargingunmolten reduced iron on the top of the coke-filled bed to form amelting section of a stock borne thereon; (d) providing solid lump fuelcomprising primarily carbon and hydrogen into the furnace to the outsidelower region of said coke-filled bed to thereby form a charge of saidsolid lump fuel therein; (e) blowing a gas comprising primarily oxygeninto said charge through at least one tuyere toward the coke-filled bedto thereby form a combustion zone or zones substantially within the areaof said charge; (f) burning and gasifying the fuel substantially withinthe combustion zone(s) by the blown oxygen to thereby generate areducing hot gas comprised of primarily carbon monoxide and hydrogen;(g) allowing said reducing hot gas to ascend through the voids of thecoke-filled bed and melt the reduced iron in said melting section by thesensitive heat of the reducing hot gas, with the resulting molten ironand iron oxide-containing slag flowing down through the voids of thecoke-filled bed in countercurrent relationship to the ascending hot gas,while having the iron oxide in the slag reduced by the coke with thecarbon in said coke dissolving in said molten iron to thereby convertthe molten iron into molten pig iron, (h) recovering the hot gas, and(i) discharging the pig iron and slag from the lowermost region of thefurnace upon collecting same therein.
 9. The process of claim 7 or 8, inwhich said shaft reduction furnace is of the moving or static bed type,or a combination type thereof.
 10. The process as recited in claim 9, inwhich said shaft reduction furnace is of the moving bed type.
 11. Theprocess as recited in claim 7 or 8, in which the gas recovered from saidmelting/gasifying furnace and fed into said shaft reduction furnace is areducing gas primarily comprising carbon monoxide and hydrogen.
 12. Theprocess of claim 7 or 8, in which the gas recovered from saidmelting/gasifying furnace is fed into said shaft reduction furnace at ahigh pressure.
 13. The process as recited in any of claims 1, 2, 7 or 8,in which said coke-filled bed is replenished by charging coke to therebymaintain the level of the coke-filled bed.
 14. The process as recited inclaim 13, in which the coke to be charged is semi-coke or coke in lumpform.
 15. The process as recited in claim 13, in which slag-formingmaterial is additionally charged as the auxiliary materials togetherwith said reduced iron and coke.
 16. The process as recited in claim 15,in which the slag-forming material charged together with the reducediron is slagged in the melting section.
 17. The process as recited inclaim 13, in which the melting section is maintained and replenished bycharging unmolten reduced iron thereto.
 18. The process as recited inclaim 1, 2, 7 or 8, in which said gas comprising primarily oxygen has anoxygen concentration of 90% or more.
 19. The process as recited in claim18, in which steam is additionally blown through said tuyere(s) tocontrol the temperature of the combustion gas generated.
 20. The processas recited in claim 1, 2, 7 or 8, in which solid lump fuel is suppliedthrough a middle opening or openings provided above tuyere(s) providedin the transition region between said upper and lower regions of thefurnace main into the outside of the lower region of said coke-filledbed.
 21. The process as recited in claim 20, in which steam isadditionally blown into said middle opening or a region adjacentthereto.
 22. The process as recited in claim 20, in which slag-formingmaterial is additionally charged through said middle opening togetherwith said solid fuel.
 23. The process as recited in claim 22, in whichsulfur contained in stock, charge and fuel(s) is removed by the slag insaid melting/gasifying furnace.
 24. The process as recited in claim 20,in which the solid lump fuel is coal, low quality or low-strength coke,semi-coke, or a mixture thereof.
 25. The process of claim 1, 2, 7 or 8,in which said melting/gasifying furnace is operated at a high internalpressure.
 26. The process as recited in clai:m 1, 2, 7 or 8, in whichthe coke ratio (coke/total feed of coke and fuel) is less than 40%. 27.The process as recited in claim 1, 2, 7 and 8, in which the reduced ironcharged has a metallization (metallic iron/total iron) of about 75% ormore.
 28. The process as recited in claim 1, 2, 7 or 8, in which thecombustion zone is maintained approximately at 1800°-2500° C.
 29. Theprocess as recited in claim 1, 2, 7 or 8, in which the melting/gasifyingfurnace is operated under such conditions that the reducing gasgenerated in the combustion zones comprises CO₂ and N₂ of 5% or less.30. The process as recited in claim 1, 2, 7 or 8, in which themslting/gasifying furnace is operated under such conditions that thereducing gas recovered from the melting/gasifying furnace comprises CO₂and N₂ of 5% or less.